Manufacturing Resources

1. Manufacturing Resources

2. Manufacturing Resources • Manufacturing begins with an idea – the goal: a product that can be made for profit. • Once a product is chosen, a company begins to prepare for production by assembling the resources needed. • There are 7 resources involved in Manufacturing: • Human • Information • Materials • Tool and Machines • Energy • Money • Time

3. Human Resources • People are an essential part of all production systems • Manufacturing systems require: • Management Skills • Professional Skills • Technical Skills • Production Skills • Quite possibly the most vital part of a manufacturing company is the Human Resources Department.

4. Human Resources • Human Resource Management duties involve: • Recruiting • Hiring • Training • Promoting/Advancement • Evaluation/Separating (firing or retirement) • Human roles within a Manufacturing Company: • Entrepreneur • Management • Labor

5. Human Resources • Entrepreneur: • The “risk taker”. Uses own money or secures investments from others to start the business. As the company becomes bigger, this person generally steps back and expects those he put in management positions to continue to make the company successful. • Management: • Managers responsibilities involve critical decisions: • Planning (present and future) • Organizing (how, when and where things are done) • Controlling (who does the work and what role they play, expenses and how much to make) • Labor/Employee: • The people who are hired to do specific work needed.

6. Human Resources • There is a need for many different kinds of people with a variety of talents or skills including: • Mechanical people with skills to operate the tools and machines • Engineering, design, and creative skilled people are needed to design products • Interpersonal skills are needed to manage the human aspects • Logical or critical thinking is needed to schedule activities and to solve problems • Many of these people have continued on after high school to a technical or 4 year college to receive training in a specific area.

7. 1. Which of the following is the goal of any production company? • Loss • Profit • Fame • Feedback

8. 2. Which of the following is not one of the resources of production? • Human • Tools • Feedback • Capital

9. 3. Human Resources refers to what? • People needed for production • Processes people use • Places people work • Money people get paid to work

10. 4. The four skills needed in manufacturing are: • Management, Professional, Technical and Production • Management, Professional, Informational and Production • Marketing, Professional, Technical and Production • Management, Bookkeeping, Technical and Production

11. Information • Information is an essential part of a production system • Manufacturing requires many types of information which is gathered from a variety of sources and affects all phases of the production process

12. Information • Information that drives Manufacturing: • Product history • Gathering Information • Marketplace Information • Production Facility Information • Environmental Impact • Laws Regulating Production Systems • Has it been produced before? • Tools, Materials & Processes • Has it been produced before? • Production Schedules • Has it been produced before? • Feedback • Has it been produced before?

13. Information Product History • Has it been produced before? • Production Engineers rely on past information about similar products when designing new ones. The space shuttle design is based on years of information gathered while making airplanes. • What was good or needed improvement from the previous model • If you research the history of aviation you would find that the first aircraft were simply gliders. The Wright Brothers experimented with wing shapes and size and found that certain shapes produced the necessary lift to keep the plane in the air. Then they combined a new technology – the internal combustion engine – with it and made the first successful manned flight. • Is there already a patent? ( A government letter of ownership of a concept or invention that prohibits someone else from making money by producing that invention without the permission of the owner)

14. Information Gathering Information • Marketplace Information • Manufacturers gather information that will help make good decisions for making their product. These decisions range from what color to make the product to how much can be charged for it. This is called Market Research. A “market” can be a place or area, an age group, a specific gender, or other identifying specifics that separate the people who might want that product from the rest. • Market Research techniques include Phone surveys, Internet surveys, in-depth product analysis via mailing, and focus groups (when people from the specific market are invited to participate in one of these groups and are asked specific questions related to the product) • Production Site Information • Before anything else begins, a production site must be selected. Decisions have to be made regarding where the most suitable site would be. • Research goes into: shipping/transportation access, location to water sources, factory/warehouse space, power availability, etc.

15. Information Laws Regulating Production Systems From the 1700s to the late 1900s there were few laws that affected manufacturing companies. There were no limits to how long a person could be forced to work, even young children of today’s elementary school age, were subjected to long work days (working past midnight in some cases) in dangerous environments with dangerous machinery. • Worker Laws • Child Labor Laws limited what age, when and where a child could work. • Minimum Wage Law prohibits an employer from paying a salary lower than the established minimum wage. • OSHA – Established in 1970 by an act of congress, the Occupational Safety and Health Administration was given the responsibility of creating and enforcing regulations to ensure the safety of all American workers.

16. Information Laws Regulating Production Systems • Consumer Safety Law • Relatively new concerns facing manufacturing is product safety. An example of the laws that affect manufacturing companies is automobile regulations such as requiring a front bumper that can resist a 5mph impact without damage, seatbelts or airbags. Recently concerns about foreign products that are made with hazardous materials such as lead paint has prompted new regulations.

17. Information Laws Regulating Production Systems • Environmental Laws • Waste by-products of manufacturing, the long term affect of discarded products were found to be having a harmful impact on the environment. There was a day when companies simply dumped their waste products into the environment. In some places drinking water was contaminated by dumped toxic liquids. The very air we breathed was being poisoned by the unfiltered exhausts of cars and smokestacks from nearby factories. • The EPA – Environmental Protection Agency (Federal government) was created, create and enforce laws that would protect the environment.

18. Information About Tools, Materials & Processes • “Time is money.” The company that can provide the consumer with the quality product they want first is going to be the winner in the market place. • Manufacturing jobs have changed over the years and are constantly requiring workers to be re-trained to keep up with the newest technology. • New materials are being created opening new possibilities for companies to improve their product or make it cost less.

19. Information Production Schedules • A production schedule shows when certain stages of an operation should be performed to produce the product in the most efficient way. • It is the job of a Production Engineer to design the most efficient order and sequence for the manufacturing of a product. They have to plan when the materials are needed. They perform “Time-Motion Studies” which time exactly how long it takes to perform every task in the production sequence and arrange the sequence where there is virtually no wasted time.

20. Information Production Feedback • The production system is constantly being evaluated for opportunities to improve it. This information is used to keep the manufacturing company ahead of it’s competitors or catch up.

21. 5. When engineers use past information about similar products when designing new ones they are using: • Ingenuity • Google • Research & Development • Production History

22. 6. A patent is…. • the plans to make product • a grant made by a government that gives the creator of an invention the exclusive right to make, use, and sell it for a set period of time. • A legal way to copy a product or invention if it’s been around for a long period of time • The governments legal permission to start a company.

23. 7. A market describes… • a place where products are bought or sold • people, processes, facilities, and capital • a place or area, an age group, a specific gender, • people, finance, feedback, capital

24. 8. What government action limited what age, when and where a child could work? • OSHA • Minimum Wage Law • Consumer Safety Laws • Child Labor Laws

25. 9.The advantage that modern tools and machines have in production companies is.. • Increased production time • Decreased production time • Tools are cheaper • More workers are needed

26. 10.What does a Production Engineer perform to document exactly how long it takes to do tasks in a production process ... • Research and Development • Time Motion Study • Marketing • Feedback Study

27. Materials • All production systems use materials to make the parts of the product from or form the product. Decisions are made during the design process as to what materials will be best for the product. (Wood would not be a good choice for making balloons) • Materials are divided into the following categories: • Raw (or natural) Materials – found in nature • Plants, minerals, air, water, etc. • Processed Materials – natural, but modified by people • Plywood, 2x4 lumber, paper… • Synthetic Materials – not found in nature • Plastics, Composites (concrete), Ceramics

28. Materials • Properties of materials: • Sensory – how the material feels, smells, or looks • Mechanical – how it reacts to loads and forces • Elasticity – the ability to return to its original shape • Plasticity – the ability to keep its new shape • Ductility – the ability to be deformed without breaking • Brittleness – Will break if deformed • Tensile Strength – The ability to resist being pulled apart • Compressive Strength – the ability to resist being pressed • Shear Strength – the ability to resist being pushed in opposite directions at the same time • Torsion Strength – The ability to resist being twisted • Fatigue Strength – The ability to withstand repeated loads • Hardness – Withstands scratches and dents • Impact Strength – Withstands sudden impacts

29. Discussion • Can you name products where each of these is a factor? • Elasticity – the ability to be altered and return to its original shape • Plasticity – the ability to be altered and keep its new shape • Ductility – the ability to be deformed without breaking • Brittleness – Will break if deformed • Tensile Strength – The ability to resist being pulled apart • Compressive Strength – the ability to resist being pressed • Shear Strength – the ability to resist being pushed in opposite directions at the same time • Torsion Strength – The ability to resist being twisted • Fatigue Strength – The ability to withstand repeated loads • Hardness – Withstands scratches and dents • Impact Strength – Withstands sudden impacts

30. Tools & Machines Successful manufacturing companies seek out the newest and best technologies to make their product with more precision and faster.

31. Energy • All manufacturing systems must have energy in order to produce • There are two forms of energy: • Potential – Stored energy (at rest) • Kinetic – Motion • The principal of Conservation of Energy: • Energy cannot be created or destroyed, it changes from one form to another

32. Capital/Expenses • The following are costs in a company: • It cost money to design, build, and operate a system. • People must be paid for labor • Materials and machines have to be purchased • Owners expect a return on the investment • Taxes must be paid

33. Time • You’ve heard the phrase – “Time is money”? • The first one to the patent office wins the right to be the exclusive owner of a product or invention. • Companies have to pay the employees for their efforts. In most cases, people are paid by the hour. The longer it takes to make a product, the more it costs to make. • To reduce the time it takes to produce a product, a company will perform “Time Management Studies” which help increase production efficiency, eliminating wasted time. This reduces cost per item because more can be produced in the same amount of time.

34. Time: Go Figure.. A company that makes 100 Widgets per hour can afford to sell it for less than their competitor that can only make 50 Widgets per hour. If the products are virtually the same, which one will you, the consumer, buy: The one that costs more or the one that costs less? Company 1: 20 employees get paid $20 per hour, produce 100 Widgets per hour. What is the labor cost per Widget? 20 x $20.00= $400.00 $400.00/100= $40.00ea Company 2: 20 employees get paid $20 per hour, produce 50 Widgets per hour. What is the labor cost per Widget? 20 x $20.00= $400.00 $400.00/50= $80.00ea

35. 11. An example of a raw material is… • Plastic • Trees • Plywood • Ceramics

36. 12. Paper is an example of… • Processed Material • Raw Material • Synthetic Material • Composites

37. 13. An example of a synthetic material is… • Plastic • Trees • Plywood • Ceramics

38. 14. Modern production involves which of the following new technologies… • More employees • Assembly line • Hand tools • Robotics

39. 15. The principal of Conservation of Energy says… • Energy is limited • We can always make more energy • Energy can never be lost or destroyed • We should conserve energy

40. 16. The word for energy at rest is… • Potential • Kinetic • Conservation • Electricity

41. 17. The word for energy in motion is… • Potential • Kinetic • Conservation • Electricity

42. 18. Which of these is an example of an expense in a manufacturing industry that could be recovered if it closed • Machines, tools and vehicles • Investments • Wages • Taxes

43. 19. The more products that can be made in an hour does what to the cost of each product? • Raises • Has no affect • Makes people want it • Lowers

44. 20. The production engineer performs this in order to find ways to speed up production… • Time Motion Study • Action Research • Production overhaul • Job study

45. Question Key • B • C • A • A • D • B • C • D • B • B B A A D C A B A D A